Electric water-heater and automatic control.



D. B. CLARK.

ELECTRIC WATER HEATER AND AUTOMATIC CONTROL.

APPLICATION FILED MAY 9. l9l6.

1,214,757. Patented Feb. 6, 1917.

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D. B. CLARK.

Patented Feb. 6, 1917.

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APPLICATION FILED MAY 9. 1915.

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In: NORRIS PEYEIZS cc. luoTO-LIYHQ. WASHINGTON. n c.

UNITED STATES PATENT OFFICE.

DUDLEY B. CLARK, OF BEMUS POINT, NEW YORK.

ELECTRIC WATER-HEATER AND AUTOMATIC CONTROL.

Application filed May 9,

To all whom it may concern:

Be it known that I, DUDLEY B. CLARK, a citizen of the United States, residing at Bemus Point, in the county of Chautauqua and State of New York, have invented certain new and useful Improvements in Electric Water-Heaters and Automatic Controls, of which the following, taken in connection with the accompanying drawings, is a specification.

The invention relates to electric water heaters and the control for the same; and the invention consists in providing a simple and eflioient water heater, with a combined hydraulic electrical control so that whenever a faucet is opened in the water system connected thereto the water will be automatically heated, provision being made for an automatic valve or gate and contacts automatically controlled by said valve, said contacts being adjustable so that, for example,

' by one adjustment of said contacts a portion of the flow of the water may be attained without heating if desired and larger flow will operate the heating mechanism, or reversely, by another adjustment of said contacts the first portion may be heated and the larger flow be cold, thus making possible an automatically controlled one pipe plumbing system; and the invention consists in the novel features and combinations hereinafter set forth and claimed.

In the drawings, Figure 1 is an elevation of the heater and hydraulic control therefor, the central portion being broken away, and a diagram of the electrical connection and mechanism for operating the heater when the water is turned on at a faucet in the system. Fig. 2 is a perspective view of the multi-contact or control switch showing the adjustability of the difierent swing contacts and the arrangement of the same. Fig. 3 is a crosswise sectional view of the heater; and Fig. 4 is a similar view showing a modification of block construction shown in Fig. 3. Fig. 5 is a lengthwise sectional view of the heater and the control valve with the pipe connection showing the arrangement a and construction of the heater and the arrangement of the valve, the different positions of the valve being shown in dotted line. Fig. 6 is a perspective view of a portion of the block upon which the wires are wound for the electrical heater, showing the construction and arrangement of the same; and Fig. 7 is a perspective view of Specification of Letters Patent.

Patented Feb. 6, 1917.

Serial No. 96,309.

the form of block shown in Fig. 4. Fig. 8 is a sectional view at line X X in Fig. 1 of the casing and an elevation of the valve and its mounting in the pipe, showing also the weight and check for the same. Fig-9 is an elevation of a heater with the casing made from a piece of common water pipe.

Like characters of reference refer to corresponding parts in the several views. The numeral 10 designates the inlet end of the pipe for the water and the numeral 11 the outlet end. The numeral 12 designates the casing for the electric heater which is suiiiciently large to take in the block 13 of non-cracking, non-absorbing insulating material, upon which the heating wires are wound in order to form the heater.

The block 13 is perforated and cut from the block edge to each perforation so as to form open ended slots which permit the winding of the resistance wires around the block to be thereby held a spaced distance from one another and from the casing 12. For this purpose a series of holes 14 are preferably bored or drilled through the block 13, and the side or edge of the block 13 is sawed through to the hole 14 thereby forming the open ended slot 15 through which the wire is passed. The opposite sides of the block 13 are arranged in the same manner so that when the wires are wrapped around the block 13, as shown in Fig. 3, they are held from contacting with one another and the casing 12.

A modified form of the block around which the resistance wires are wrapped is shown in Figs. 4 and '7 which is especially adaptable for quick heating if desired wherein a large surface of the heating coil is required in proportion to the amount of water passing therethrough. The change in the form of the block consists of a square or nearly square block 41 with corner perforations and slots 42, which perforations pass diagonally through each corner thereby giving an exposure of the resistance wire on each side of the block 41 yet permitting the easy wrapping of said resistance wire around the block the same as upon block 13.

It is apparent that either of the blocks may be placed in a lathe and the wires held a spaced distance apart corresponding to the open ended slots 15 and 42 and the wires will be quickly and evenly drawn into place around the blocks 13 and 41 so that said block can be connected into the heating system as hereinafter described and said wires will be held a spaced distance from one another and the casing.

The block 13 is wired and connected in the following manner: Three wires are introduced together as at 17 into the inlet pipe 10 through the single insulating insert 16, which construction prevents leakage from the water under pressure in the pipe 10. The three wires pass one to each of the first three holes 1 1-, one wire to each hole and slot and are then progressively wrapped around the block 13 spacing from one anoth r so as not to contact with one another or with the casing except through the water.

i The three wires 18, 19 and 20, which enter at 17, pass out separately and through separate insulation inserts 21, s9- and 23 to their respective relays, the wire 18 connecting to the double pole relay switch 24, the wire 19 to the single pole relay switch 50, and the wire 20 to the single pole relay switch 51. The three wires 17 connect to one of the contact plates 25 of the double pole relay switch 2%, which connects with the contact plate 26 to which the wire 27 is connected which wire 27 connects to the source of electric energy.

The hy raulic control of the electric heater consists of the swing or gate valve 28 which is mounted on the valve rod 29, which rod 2-9 is revolubly mounted in the block 30 with oiling holes and screw closures 31 therefor to oil the rod 29 so that the valve or gate 28 shall work freely whenever the water moves in the pipes 10 and 411. The rod 29 is provided with a set nut 32 which bears against the block 30 and a set-screw 33 which has a point bearing against the angle of the rod 29 where it turns downward in the contact valve or arm The weight 35 is adjustably and slidably attached on the swing arm 3% so as to hold said weight any desired point by means of the set screw 36. A. casing 37 is provided over the valve arm 34, which valve arm acts as a contactingswing end and also as a check, stopping against the post 89, so that while the water can flow out of the end 11 it cannot flow back 'ard into the electric heater,

The valve block is made in two parts 30 and 38 so that the block can be taken apart whenever the valve 28 needs repair. A partial closure is preferred for the opening leading to the valve 28, formed by the downwardly jutting wall 40, which focuses the water upon the valve 28, thereby insurthe action of said valve.

The swing contact switch consists of the valve arm 34 on the rod 29 for the valve 28 which arm 3% has a contact plate 4-3 thereon, and a number of swing bars A and 45, which have contacts on both sides thereof and which are pivotally attached at their to each of the magnetic switches.

upper ends by means of screws 16 in a slot 17 in the support bar attached to the block 30 so that they may be spaced apart from one another or from the valve arm 3t according as it is desired to control the heating of the water in the water pipes. A fixed contact post 18 is provided which limits the upward movement of the contacting bars or arms, which post 4-8 is fixed at the upper limit of the movement of the valve 28, that is, when the valve is wide open, permitting the full flow of the water through the pipes 10 and 11. i

The valve arm 34: is connected by a wire 4-9 to the double pole switch 24:. The upper end of the pendant bar 41- is connected by the wire 52 to the source of the electric current to operate the magnetic switches 24-, 50 and 51, the other side of the circuit being shown by the wire 53 which is connected The upper end of the contact bar 45 is connected to the single pole switch 50, and the fixed contact 48 is connected to the single pole switch 51. The three magnetic switches 2 1, 50 and 51 are in turn connected to the wire 54- which connects to the source of thermo electric energy on the opposite side of the current from wire 27, suitable contact plates being provided for said connections with said switches.

The operation of the electric heater is as follows: When a faucet in the water system wherein the heater is attached is opened the water begins to How and passes through the pipe 10, flowing around the resistance wires 18, 19 and 20 and block 18 or 14- and opening the swing valve 28 sufiiciently to cause contact of the valve arm 3 1 with the first contact bar 1 1, thereby actuating the double pole magnetic switch 24-, which in turn connects the source of power with the first resistance wire 18. If the faucet is further opened the force of the water swings the contact bar 44 against the contact bar and at the same time keeps arm and bar it in contact which operates the single pole switch 50 connecting the second wire 19 ith the source of electrical energy, and should the faucet be turned wide open the valve arm 34: and bars 6% and t5 will be forced upward against the fixed contact 18 thereby actuating the next single pole switch 51 and connecting the source of electric energy to the wire 20 as well as wires 18 and 19 thereby obtaining the full heat of the three resistance wires 18, 19 and 20 with the full force of the water through the pipe 10 and 11.

It is obvious that the connection to the source of electrical energy which heats the resistance wires may be controlled by the swing contact switch as desired. For eX- ample, if it is desired that the first portion of the flow of the water should be cold the electrical. connection to the upper end d6 of the two adjustable contact bars 4st and as are moved toward the fixed contact 48 thereby permitting theflow of a half open faucet to run cold before heating contact is made, but if it is opened farther, contact is at tained and the operation of the electric heater is as hereinbefore described. Thus, any desired arrangement of the heating of the water flow can be attained by the simple adjustment of the contacting bars H; and 45. A greater or lesser number of contact bars may be attached to the support bar 55 and not depart from my invention. It will be understood, however, that the contacts are notdepended on to carry the total power required to heat the water but only suilicient electricity passes through them to operate the switches, which are a standard make of relay switch, and that said switches accordingly are not subject to the wear and tear of arcing from heavy current and should therefore last indefinitely.

The action of the water and gravity are the only forces used to operate the valve 28. The vater flowing through the pipe and heater when a faucet is opened, opens the valve and makes the contact or contacts. hen the water flow ceases from the closing of the faucet the valve 28 is returned to its normal position by its own weight and the adjustable weight 35 on the valve arm 3 1- on the rod 29 which hingingly supports valve 28, since the flow of the water automatically controls the heating element and is always flowing when the current is turned on. Since it turns on said current by its flow there is accordingly no danger of said heating element burning dry or overheating, the Water always surrounding said heating element.

The heater and automatic control may be installed anywhere desired in the water pipe system. Thus connections may be had at the ends of the heater casing 12 through the capped pipes 56 for connection with the hot water heating system of a building, and by means of an individual control switch the electric heater may be used to heat the building without interfering with its use as an automatic water heater for the hot water faucets, supplying the water to said faucets without any change in said faucets. By the automatic control the heater uses the electricity only while the water is flowing through said pipes and the heater.

By my simple swing bar control and swing valve with valve arm or pendant end 3% of the rod 29, both hot and cold water may be drawn from the same pipe, the water being cold until the valve arm 3%: contacts the first bar 44 thereby turning on the first heat, the successive heats being added as an additional bar or bars or contacts may be made by the further opening of the valve 28.

My simple electric heater construction for water can be used in a common water pipe of sufiicient size, particularly that form shown in Figs. 4 and 9, though the form shown in Figs. 3 and 5 is adaptable to such a pipe. It is obvious that the inlet and out let pipes 10 and 11 may be inserted in the opposite ends of a piece of common pipe, as shown in Fig. 9, thereby making a very simple heater by the insertion of the heating element within the heating section of said pipe at low cost and as easily wired as in the larger casing shown in Figs. 1 and 5.

The insulated inserts 16, 21, 22 and 23 are preferably of molded insulation material like mica within which the resistance wire or wires are firmly embedded,the molded insulation being pressed about the same and asuitable thread cut on the outer surface of the insulation insert for screwing into the pipe connection to the heater with a water tight joint, both for the resistance Wire or wires and for the molded insulation insert.

It is obvious that the electrical contact 43 on the valve arm 3% and the contact surfaces on the swing or hinged bars 4st and 45, on account of the spaced relation of said arm and bars and their pivoting from different centers, will wipe or draw across one another when actuated thereby aiding greatly in keeping said contacts clean for perfect contact with one another.

I claim as new:

1. An automatic control for an electric water heater comprising an electric heating element arranged for multiple heats for the water, and variable flow controlled means for said multiple heats to change the heating capacities with predetermined changes in the velocity of the water flow.

2. An electric Water heater comprising an electric heating element provided with multiple heating means for said water, and a progressive, flow-actuated electrical control for progressively energizing said multiple heating means to obtain increased heating capacity with an increased velocity of the flow of the water.

3. An automatic control for an electric water heater comprising an electric heater having a plurality of resistance wires to heat the water, inlet andoutlet pipes for the water to said heater, a valve in said outlet pipe actuated by the flow of the water, and a switch actuated by said valve havin a plurality of electric contacts connected to said resistance wires to obtain different degrees of heat as desired by the action of said valve.

4:. An automatic control for an electric water heater comprising a plurality of resistance Wires for heating the water to obtain different degrees of heat therefrom, inlet and outlet pipes at opposite ends of said heater, a valve in said outlet pipe actuated by the flow of the water, an electric switch actuated by said valve, and a plurality oi adjustable electric contacts on said switch connected to said resistance wires one to each wire to adjust the heating of the water by the velocity of the flow of said water.

5. A device of the class described comprising an electric water heater, a plurality of spaced resistance wires in said heater, in let and outlet pipes in the opposite ends of said heater, an electrically connected valve in said outlet pipe to be actuated by the flow of the water, and a plurality of swing contact bars in spaced relation to said valve and connected to said resistance wires one to each wire to successively connect said resistance Wires according to the flow of water through said outlet pipe.

6. An automatic control for an electric water heater comprising an electric heating element arranged for multiple heats for the water, a swing valve attached to a rotatively mounted rod in the water outlet pipe from said heating element to be actuated by the flow of the water, one end of said rod extending downward in a valve arm, a plurality of contact bars hinged in spaced relation to one another and said valve arm, electrical contacts on said valve arm and contact bars to be wiped across one another when in contact by the hydraulic action of said valve, and electrical connection between said valve arm and bars and said heatingelement to control the same by the action of said valve.

7. An automatic control for an electric water heater comprising a resistance wire in said heater to heat the water, an inlet pipe at one end and an outlet pipe at the other end of said heater for the water to pass through said heater, a swing valve in said outlet pipe actuated by the movement of the water, a contact arm on said valve actuated thereby, an electrical contact a spaced distance from said contact arm connected to said resistance wire and the source of electrical energy by a relay switch to turn on the heat when said valve arm connects with said contact and thereby draw cold or hot water from a single pipe as desired.

8. An automatic control for an electric water heater comprising a plurality of spaced resistance wires therein to heat the water, an inlet pipe at one end and an outlet pipe at the other end of said heater for the water to pass through said heater, a swing valve in said outlet pipe actuated by the movement of the water, a weighted contact arm on said valve actuated thereby, and a plurality of movable contacts in spaced relation to said weighted contact arm and electrically connected to said resistance wires one contact to each wire and to the source of electrical energy by relay switches one switch to each contact to turn on the heat when said valve arm connects with one or more of said contacts to thereby run cold and hot water from a single pipe having different degrees of heat.

9. An electric water heater comprising a tubular casing having an inlet at one end and outlet at the other for the water to run through said casing, an insulation block having spaced open ended slots in the edges contacting said casing, resistance wires wound around said block in spaced relation in said slots, said casing having space between said block and the casing inner wall for the passage of the water around said resistance wires and through said casing, and molded insulation inserts for said wires screwed into said casing to admit said wires into and out of said casing.

10. An electric water heater and control therefor comprising a tubular casing having an inlet pipe at one end and an outlet pipe at the other for the water to pass through, a block of insulation in said casing, a plurality of resistance wires wound in spaced relation on said block to heat the water, a swing valve in said outlet pipe having a valve contact arm operated by the flow of the water through said outlet pipe, an adjustable weight on said valve arm, a plurality of adjustable swing contact bars in spaced relation to said valve arm, and relay switch connection respectively between said contact bars and said resistance wires and the source of electrical energy to control the heating of the water by the movement of said water through said valve and heater.

11. An electric heating means for fluid including an electric heater, and automatic means controlled by the velocity of the passage of the fluid for proportioning the heating capacity of the heater to the flow of the fluid.

12. A heating device for fluid conduits, including an electric heater having different heating units, and means controlled by the passage of the fluid through the conduit for effecting progressive energization of the units of said heater proportionate to the velocity of the fluid flow.

13. A heating device for fluid conduits, including a series of heating units arranged in the conduit, a swingable member arranged in the conduit responsive to the flow of fluid and to varying distances dependent upon the velocity of the fluid flow, and means for energizing each heating unit operable by said swingable member in succession as the velocity of the fluid flow is increased.

14. A heating device for fluid conduits, including an electric heater, and swingable means actuated by the impact of the fluid to diflerent positions for effecting varying energization of said heater according to the position at which said means is swung as determined by the velocity of flow of the fluid.

15. A heating device for fluid conduits, including an electric heater, means to eii'ect varying energization of said heater including spaced contacts, and means controlled by the velocity of floW of the fluid to successively engage said contacts for varying the heating capacity according to such velocity.

16. A heating device for fluid conduits, including an electric heater, means to eflect varying energization of said heater including spaced contacts, and swingable means controlled by the velocity of flow of the fluid to engage said contacts successively and in proportion to the flow of the fluid for varying the heating capacity according to such velocity.

In testimony whereof I have afiixed my signature in the presence of two Witnesses.

DUDLEY B. CLARK. Witnesses:

H. A. SANDBERG, D. LAWRENCE CARLSON.

Copies of this patent may he obtained for five cents each, by addressing the Commissioner of Patents, Washington, D. 0. 

